2974
Optimization of Operating Condition of REFLUX Flotation Cell
(RFC) for Copper Sulfide Ore
Mustafa K. Guner, Pshem Kowalczuk
Department of Geoscience and Petroleum, Faculty of Engineering, Norwegian University of Science and Technology
ABSTRACT: The mining industry faces challenges in dealing with declining cut-off grades, complex and poly-
mineralized ores, while also complying with stringent environmental regulations. Innovating and integrating
the latest technologies into flotation cells plays a crucial role in overcoming these recent challenges. REFLUX™
Flotation Cell (RFC™) is a flotation device with a new design that has recently been introduced to the mineral
processing market and has shown very promising results in different flotation applications in the literature and
industrial activities. In this study, the operating conditions of RFC (i.e., bias, feed, wash water, and gas fluxes)
were optimized in the flotation of copper sulfide ore (Kupferschiefer) in the RFC™ using a response surface
design (design of experiments, DOE). The levels of the factors are 3, 4, and 5 cm/s for feed flux 1, 2, and
3 cm/s for gas flux 0.75, 1.0, and 1.25 cm/s for wash water and 0, 0.25, and 0.5 cm/s for bias. The kinetic
flotation test procedure was performed in the rougher stage and the results were interpreted in terms of recovery
and grade of Cu. Preferred operating conditions for copper sulfide ore were recommended for future activities
with RFC.
INTRODUCTION
Flotation concentrator plants face various obstacles, includ-
ing the demand for higher throughput, decreasing cut-off
grades, and reduced degrees of liberation, as well as the
challenge of dealing with complex and poly-mineralized
ores. These challenges are compounded by significant costs
associated with energy, water, maintenance, and reagent
consumption (Mudd, 2010). The general aim is to reduce
the particle size distribution of the processed material to
achieve liberation and to increase the volume of flotation
cells in order to maintain the production rate with mate-
rial that has a lower cut-off grade (Mesa and Brito-Parada,
2018). Since the first industrial application of flotation,
the size of flotation cells has significantly increased from
10m3 to 600m3 (Carter, 2017). As processing finer mate-
rial and achieving higher throughput becomes a necessity
for the flotation industry, new innovations and technolo-
gies are needed (Hassanzadeh et al., 2022). Recently, the
REFLUX ™ Flotation Cell (RFC ™) has shown significant
promise, providing a comprehensive solution for process-
ing high throughput with varying particle sizes (Dickinson
et al., 2014 Jiang et al., 2017, Parkes, 2024).
The main operating parameters in RFC are feed (jf),
gas (jg), wash water (jw) fluxes and bias (jb). Flux (cm/s)
is the term used superficial velocity of a flow calculated
by dividing the volumetric flow by cross-sectional area
(Ireland and Jameson, 2006). Feed flux directly determines
throughput and flotation kinetics (Tabosa et al., 2012). In
addition to operational advantages (e.g., production rate),
the feed flux also affects hydrodynamics properties. Increase
in the feed flux decreases the bubble size diameter (Jiang et
al., 2014), and increases shear rate in the downcomer which
is one of the main parts of RFC (Galvin and Dickinson,
Optimization of Operating Condition of REFLUX Flotation Cell
(RFC) for Copper Sulfide Ore
Mustafa K. Guner, Pshem Kowalczuk
Department of Geoscience and Petroleum, Faculty of Engineering, Norwegian University of Science and Technology
ABSTRACT: The mining industry faces challenges in dealing with declining cut-off grades, complex and poly-
mineralized ores, while also complying with stringent environmental regulations. Innovating and integrating
the latest technologies into flotation cells plays a crucial role in overcoming these recent challenges. REFLUX™
Flotation Cell (RFC™) is a flotation device with a new design that has recently been introduced to the mineral
processing market and has shown very promising results in different flotation applications in the literature and
industrial activities. In this study, the operating conditions of RFC (i.e., bias, feed, wash water, and gas fluxes)
were optimized in the flotation of copper sulfide ore (Kupferschiefer) in the RFC™ using a response surface
design (design of experiments, DOE). The levels of the factors are 3, 4, and 5 cm/s for feed flux 1, 2, and
3 cm/s for gas flux 0.75, 1.0, and 1.25 cm/s for wash water and 0, 0.25, and 0.5 cm/s for bias. The kinetic
flotation test procedure was performed in the rougher stage and the results were interpreted in terms of recovery
and grade of Cu. Preferred operating conditions for copper sulfide ore were recommended for future activities
with RFC.
INTRODUCTION
Flotation concentrator plants face various obstacles, includ-
ing the demand for higher throughput, decreasing cut-off
grades, and reduced degrees of liberation, as well as the
challenge of dealing with complex and poly-mineralized
ores. These challenges are compounded by significant costs
associated with energy, water, maintenance, and reagent
consumption (Mudd, 2010). The general aim is to reduce
the particle size distribution of the processed material to
achieve liberation and to increase the volume of flotation
cells in order to maintain the production rate with mate-
rial that has a lower cut-off grade (Mesa and Brito-Parada,
2018). Since the first industrial application of flotation,
the size of flotation cells has significantly increased from
10m3 to 600m3 (Carter, 2017). As processing finer mate-
rial and achieving higher throughput becomes a necessity
for the flotation industry, new innovations and technolo-
gies are needed (Hassanzadeh et al., 2022). Recently, the
REFLUX ™ Flotation Cell (RFC ™) has shown significant
promise, providing a comprehensive solution for process-
ing high throughput with varying particle sizes (Dickinson
et al., 2014 Jiang et al., 2017, Parkes, 2024).
The main operating parameters in RFC are feed (jf),
gas (jg), wash water (jw) fluxes and bias (jb). Flux (cm/s)
is the term used superficial velocity of a flow calculated
by dividing the volumetric flow by cross-sectional area
(Ireland and Jameson, 2006). Feed flux directly determines
throughput and flotation kinetics (Tabosa et al., 2012). In
addition to operational advantages (e.g., production rate),
the feed flux also affects hydrodynamics properties. Increase
in the feed flux decreases the bubble size diameter (Jiang et
al., 2014), and increases shear rate in the downcomer which
is one of the main parts of RFC (Galvin and Dickinson,
